DECLARATION

Internship program is newly adopted in the educational curriculum of Ethiopia for engineering
students. It is given to students of fourth year and in the second semester. We have done this
internship program for two months in Asella malt factory. We declare that the project work
entitled as ‘Design of portable crane is an authentic record of our own work carried out at Asella
malt factory; as required for the two months internship semester for the award of ‘Internship
evaluation’ under the guidance of our advisor Mr. Bilal Jemal from June 2021 to August 2021.

Advisor’s Name Signature Date

1. Bilal Jemal ------------ --------------------

2. Hana Beyene ------------ --------------------

i
ACKNOWLEDGEMENT
We consider our self as a very lucky individual as we were provided with an opportunity to be a
part of Asella malt factory. The internship opportunity we had with Asella Malt Factory was a
great chance for learning and professional development. Therefore, we are also grateful for
having a chance to meet so many wonderful people and professionals who led me though this
internship period. Bearing in mind previous we are using this opportunity to express my deepest
gratitude and special thanks to my supervisor Mr. Eshetu Mechanical and Production section
leader of Asella Malt Factory who in spite of being extraordinarily busy with his duties, took
time out to hear, guide and help us on the right way. We also thank the honors workers of the
factory for their brilliant guidance.

ii
ABSTRACT
This intern ship program report consists of the back ground of Asella malt factory. It includes its
main services, its main customers and its users of its services, it over all organization, work flow
and activity of each department. On the other hand this intern ship report focuses on the overall
intern ship experience. This contains the intern ship benefits that we gain in the company
including Improvement in our practical skill, theoretical knowledge, intern personal
communication skill, team playing skill, leader ship skill, work ethics principles and
entrepreneurship skill.

On the second part we concerns the design of portable crane uses a hydraulic system to lift a
heavy loads. The main advantage of the project is having detail design of part. In this project we
designed a portable crane which can lift a heavy load with a maximum capacity of 3 ton. The
crane has two loaded side bars to make the base and two links (i.e. Vertical column and boom)
connected each other by using pin joint. The Vertical column is secured on the cross bar that is
welded to the side bars making the base using bolt connection. There are also other bars for
supporting purpose which are connected to the basic link (vertical column) using bolt
connection. The crane uses four wheels, of which two of them in the front are connected to the
base using permanent joint and the rear wheel is connected to the base using roller. Since the
crane operates hydraulically there is piston cylinder device which is connected to the vertical
column and boom for lifting up and down the objects. The maximum carrying capacity 3 ton,
and maximum lifting height is 3.14m from the ground by using hand pump.

iii
NOTATION
A…………………. Cross sectional area

Aw…………………Area of wire

b…………………..Width / depth

C…………………..Stiffness constant

c……………………Distance b/n axis and end fiber

d……………………nominal diameter

dc…………………...Core diameter

dh…………………...Diameter of hinged pin of piston

di……………..……..Inner diameter

dp………….………. Diameter of piston

do…………………… Outer diameter

dr…………………… Diameter of rope

dw………………..…. Diameter of wire

E…………………….. Modulus of elasticity

e…………………….. .Eccentricity

M……………………..Bending moment

iv
TABLE OF CONTENTS

DECLARATION..............................................................................................................................i
ACKNOWLEDGEMENT...............................................................................................................ii
ABSTRACT...................................................................................................................................iii
NOTATION....................................................................................................................................iv
List of figures...................................................................................................................................1
List of tables....................................................................................................................................3
CHAPTER 1....................................................................................................................................4
INTRODUCTION TO ASELLA MALT FACTORY....................................................................4
1.1 Brief History of Asella Malt Factory.....................................................................................4
1.2 Vision of AMF.......................................................................................................................4
1.3 Mission of AMF.....................................................................................................................4
1.4 Goal of AMF..........................................................................................................................4
1.5 Values of AMF...................................................................................................................5
1.6 Main customers..................................................................................................................5
1.1.6 Organization Structure and Work Flow..........................................................................6
CHAPTER 2....................................................................................................................................7
DESCRIPTION OF PROCESSES OF DRY STATE.....................................................................7
2.1 Introduction to Barley Malting..............................................................................................7
2.2 The Sequential Process of Asella Malt Factory.....................................................................8
1. Intake barley......................................................................................................................8
2. Hopper...............................................................................................................................9
3. Chain conveyor.................................................................................................................9
4. Elevator..............................................................................................................................10
5. Pre cleaner..........................................................................................................................10
7. Weight balancing machine.................................................................................................11
9. Grain cooler........................................................................................................................12
10. Screening and grading machine.......................................................................................13
11. Drum sieve..................................................................................................................14
12. Weighting....................................................................................................................14
 2.3 Steeping................................................................................................................................14
1. Steeping tank...................................................................................................................15
2. Carbon dioxide extraction fan.........................................................................................15
3. Aeration fan (blower)......................................................................................................16
4. Water pump........................................................................................................................16
5. Spray pump.........................................................................................................................17
6. Distributor..........................................................................................................................17
7. Discharge pump..................................................................................................................17
2.4 Hydraulic components.........................................................................................................17
CHAPTER 3..................................................................................................................................18
3.1 Germination process............................................................................................................18
1. Hydraulic system.............................................................................................................18
A. Electric motor..................................................................................................................19
2. Electric system................................................................................................................20
a. Germinating box.............................................................................................................21
3. Mechanical systems............................................................................................................22
4. Old germinating room........................................................................................................22
3.2 Cooling process....................................................................................................................23
3.2.1 Radiator.........................................................................................................................23
3.2.2 Compressors..................................................................................................................24
3.3 Cooling system.....................................................................................................................27
CHAPTER 4..................................................................................................................................28
KILNING PROCESS (DRY STATE)...........................................................................................28
4.1 Kilning process....................................................................................................................28
4.1.1 Classes of kilning room.................................................................................................28
4.2 Boiler....................................................................................................................................29
4.2.1 Furnace tanker...............................................................................................................29
4.2.3 Electrical boiler.............................................................................................................34
4.3 Boiler water treatment..........................................................................................................36
4.4 Polishing machine................................................................................................................39
4.5 Cyclone................................................................................................................................40
4.6 Dispatching machine............................................................................................................40
 4.7 Belt Conveyors.....................................................................................................................40
4.8 Mechanical workshop..........................................................................................................41
4.8.1 Production section.........................................................................................................41
4.8.2 Welding Section............................................................................................................43
CHAPTER 5..................................................................................................................................45
Improving team playing skill.....................................................................................................45
Improving Leadership skill........................................................................................................46
Understanding about work ethics and related issues.................................................................46
Entrepreneurship skill................................................................................................................47
Improving interpersonal communication skill...........................................................................47
PART II.........................................................................................................................................49
CHAPTER 1..................................................................................................................................49
1.1 INTRODUCTION...............................................................................................................49
Types of Portable Crane.........................................................................................................49
1.2 Problem of Statements.........................................................................................................50
1.3 Proposed solution.................................................................................................................50
1.4 Objectives.............................................................................................................................50
1.4.1 General Objectives........................................................................................................50
1.4.2 Specific Objectives........................................................................................................51
1.5 Methodology........................................................................................................................51
1.6 Significance..........................................................................................................................51
1.7 Limitation.............................................................................................................................52
CHAPTER 2..................................................................................................................................53
2.1 LITERATURE REVIEW........................................................................................................53
CHAPTER 3..................................................................................................................................55
WORKING PRINCIPLE AND 3D...............................................................................................55
CHAPTER 4..................................................................................................................................58
DESIGN ANALYSIS OF COMPONENTS..................................................................................58
4.1 Design of Vertical Column..................................................................................................58
4.2 Design of Boom...................................................................................................................60
4.3 Design of Crane Hook..........................................................................................................61
4.4 Design of Base Plate............................................................................................................64
 4.5 Design of Center Connecting Bar........................................................................................67
4.6 Design of Pins......................................................................................................................68
4.7 Design of Hydraulic System................................................................................................70
a. Design of Cylinder..............................................................................................................71
b. Design of Piston..............................................................................................................72
c. Design of Piston Rings....................................................................................................73
d. Design of Piston Barrel...................................................................................................74
4.8 Lifting Height.......................................................................................................................75
CHAPTER 4..................................................................................................................................77
COST ANALYSIS, MANUFACTURING AND MATERIAL SELECTION.............................77
A. COST ANALYSIS.............................................................................................................77
B. MANUFACTURING PROCESS.......................................................................................78
CHAPTER 5..................................................................................................................................79
5.1 RESULT AND DISCUSSION............................................................................................79
5.2 CONCLUSION....................................................................................................................80
5.3 RECOMMENDATION.......................................................................................................81
5.4 REFERENCE.......................................................................................................................82
5.5 APPENDIX..........................................................................................................................83
Internship Report And Design Of Portable Crane 2013/2021

List of figures
Figure 1. 1 Company organization and work flow..........................................................................6

Figure 2. 1 Asella malt factory work flow.......................................................................................8

Figure 2.2 Barley intake..................................................................................................................9
Figure 2.3 hopper.............................................................................................................................9
Figure 2.4 chain conveyor.............................................................................................................10
Figure 2. 5 pre cleaner...................................................................................................................10
Figure 2. 6 magnetic separator.......................................................................................................11
Figure 2. 7 weight balancing machine...........................................................................................11
Figure 2. 8 silo...............................................................................................................................12
Figure 2. 9 grading machine..........................................................................................................14
Figure 2. 10 steeping tank..............................................................................................................15
Figure 2. 11 Carbon dioxide extraction fan...................................................................................16
Figure 2. 12 aeration fan................................................................................................................16
Figure 2. 13 Water pump...............................................................................................................16
Figure 2. 14 distributor..................................................................................................................17

Figure 3. 1 new germination box...................................................................................................21

Figure 3. 2 ammonia recycle and processes..................................................................................27

Figure 4. 1 furnace boiler...............................................................................................................33

Figure 4. 2 electric boiler...............................................................................................................34
Figure 4. 3 components of electric boiler [5]..................................................................................35
Figure 4. 4 water treatment............................................................................................................37
Figure 4. 5 cyclone........................................................................................................................40
Figure 4. 6 lathe machine...............................................................................................................41
Figure 4. 7 drilling machine...........................................................................................................42
Figure 4. 8 Hydraulic Press Machine............................................................................................42
Figure 4. 9 milling machine...........................................................................................................43

Figure 4. 1 furnace boiler...........................................................................................................................33

Figure 4. 2 electric boiler...........................................................................................................................34
Figure 4. 3 components of electric boiler [5]...............................................................................................35
Figure 4. 4 water treatment......................................................................................................................37
Figure 4. 5 cyclone.....................................................................................................................................40
Figure 4. 6 lathe machine..........................................................................................................................41
Figure 4. 7 drilling machine.......................................................................................................................42

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Figure 4. 8 Hydraulic Press Machine..........................................................................................................42

Figure 4. 9 milling machine........................................................................................................................43
Figure 4. 10 Vertical column......................................................................................................................57
Figure 4. 11 Cross-section of vertical column............................................................................................57
Figure 4. 12 Boom connected with column...............................................................................................59
Figure 4. 13 Boom section view.................................................................................................................59
Figure 4. 14 Plane view of crane hook.......................................................................................................61
Figure 4. 15 Cross section of crane hook...................................................................................................61
Figure 4. 16 Base plate..............................................................................................................................63
Figure 4. 17 Vertical column......................................................................................................................63
Figure 4. 18 Boom cross section................................................................................................................64
Figure 4. 19 Vertical column support.........................................................................................................64
Figure 4. 20 Center connecting bar...........................................................................................................66
Figure 4. 21 Pins of portable crane............................................................................................................67
Figure 4. 22 Pin supporting vertical column and boom.............................................................................68
Figure 4. 23 height of the crane at maximum height.................................................................................74
Figure 4. 24 Height of the crane at minimum height.................................................................................75

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List of tables
Table 1 Table of cost of material...................................................................................................76

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CHAPTER 1

INTRODUCTION TO ASELLA MALT FACTORY

1.1 Brief History of Asella Malt Factory

Asella malt factory is Asella Malt Factory is the first producer of Malt in Ethiopia since 1984
GC. It was established on the main road of Addis Ababa to Asella near Kulumsa Agricultural
Research Center with 30-million-birr capital on 14.7 hectares of land in September 1/1984G.C.
Location of Asella malt factory is 167km southern of Addis Ababa & 8km from Asella town in
Kulumsa village. It was founded on the eve of the founding of worker’s party of Ethiopia & the
tenth anniversary of the Ethiopia revolution. The factory was established with the aim of
producing and providing malt for the existing breweries in the Country. [1]

1.2 Vision of AMF

Producing universally standardized quality malt production and transfer the country’s foreign
market supply.
1. To fulfill quality policy of the World.
2. To supply inside the country, outside the country & become famous malt factory.
1.3 Mission of AMF

In collaboration with people, investors and aid organization to study roads at different status and
then construct, maintain and secure them with corresponding technology and reasonable expense
in order to bring well organized development for the regional society. Develop positive attitude
about road and its related cautions. Take knowledge transfer in road construction

1.4 Goal of AMF

 To increase malt supply & quality to give support for investigator (researcher) of barley
for achievement of the goal.
 By using modern technology to fulfill quality policy of the World to produce quality
malt.
 To become famous malt producer in the World & to save economy of country which is
purchased malt from foreign country & to take responsibility development of the country.

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1.5 Values of AMF

 Quality, accountability, justices and loyalty are the assets of the company.
 Quality service and assuring remarks are the measures of success.
 Focus on developmental activities that participates all society.
 Follow best management method to use assets.
 Work together and wither the success or the failure will be ours.
 Following professional ethics is our quality.
 Giving more priority for customers.

1.6 Main customers

Asella Malt Factory has supplying barley malt to domestic brewery factory in high quality and
quantity

The main customers of Asella Malt Factory are; [1]

 BGI Ethiopia brewery factory,
 Bedelle brewery factory
 Meta brewery factory
 Harar brewery factory.
 Raya brewery factory.
 Dashen brewery factory
 Heineken brewery factory
 Habesha brewery factory

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1.1.6 Organization Structure and Work Flow

General Assembly

Board of Director

General Manager

Production and technique director Administrative and human power

management

Internal audit
Finance office manager

ICT Manager Ethical and anti-

corruption Manager

Comers planning secretary

Agricultural production manager

Executive Secretary

Human Finance Marketing Production & Quality Procurement & Supply

Resource & Sales Technique Assurance
Service

Electrical
Production Auto mechanical Mechanical
Maintenance Section
Section Section Maintenance Section

Figure1. 1 Company organization and work flow

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CHAPTER 2

DESCRIPTION OF PROCESSES OF DRY STATE

2.1 Introduction to Barley Malting

Barley is the fourth largest cereal crop in the world with the share of 7% of global cereal
production. Barley is an important annual cereal plant which belongs to the genus Hordeum of
the grass family Poaceae and is majorly used in cooking and making malts. It is a very ancient
cultivated grain. It has nutty flavor and lighter in appearance. The demand for barley based malt
is higher when compared to other grain like wheat, rye, oat and corn due to their ease of
availability and crucial role in the manufacturing of malt for alcohol. Malting refers to the grain
which is softened by water and then it is germinated by soaking in the water and then halted from
germinating by hot air and then dried. Or it refers to the grain which is sprouted and then dried
by a method known as malting. It is made of barley and usually used for brewing and distilling.

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2.2 The Sequential Process of Asella Malt Factory

Pre cleaning Magnetic separator Weighting

Barley intake

Grading

Kilning Steeping Weighting

Germination

Polishing Cleaning Dispatching Sell

Figure 2. 1 Asella malt factory work flow

Barley malt is a natural food product developed by germinating and drying of barley under
carefully controlled process conditions. Malting process classified into three separate stages:-

1. Steeping (dry state)

2. Germination (wet state)
3. Kilning (dry state)

1. Intake barley
Barley intake is the initial process in the malting. Barley intake is passage through which
barley is moved by means of gravity. Due to gravity force the barley is passes into hopper.

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Figure 2.2 Barley intake

2. Hopper
Hopper is storage container used to dispense barley through the use of a vertically or inclined
plane channel, passage through which barley is moved by means of gravity.

Figure 2.3 hopper

3. Chain conveyor
A chain is a transmission element made up series of pin-connected links. The chain conveyor is a
type of conveyor system used for moving barley or malt horizontally throughout the factory. It
has the capacity of transporting 600 quintals per hour. This chain conveyor consists of:
 Motor- is main part of chain conveyor which is used to rotate the chain.
 Link -is small part of chain and a series of connected links form a chain.
 Wings or pedestals- are extended on the chain and are used to push the barley or malt to
its given destination.

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Figure 2.4 chain conveyor

4. Elevator
It’s a mechanism used to transport barley or malt vertical transportation. The elevator consists of:
 Drum- is the circular shafts made up of stainless steel material
 A belt- is a flexible power transmission element that seats tightly on a set of drums used
for transmission and also to carry the buckets.
 Motor- is used as a means to drive the drum.
 Shaft- is a power transmission element fixed to the drum on one end and motor on the
other
 Bucket- is a concave structure that is mounted on the belts used to contain the barley.

5. Pre cleaner
Due to the gravity force the barley from the intake elevator slides in to the pre cleaning machine.
This machine has brush and rotating drum sieve, so that over- sized and unwanted materials such
as ropes, hull, chaff, bran, dung, etc…are cleaned. It has motor, which is used to rotate the drum
sieve and as it rotates the brush rubes against it and oversized and unwanted materials are
collected by the brush to be discharged through an outlet separated from the barley.

Figure 2.5 pre cleaner

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6. Magnetic separator
Magnetic separator is the machine that consist magnet; it is used to attract the magnetic material
from the barley. It consists magnets so that the magnetic materials such as nails, piece of metals
are attracted by this magnet from the barley.

Figure 2. 6 magnetic separator

7. Weight balancing machine
The barley that is cleaned by the pre cleaner and magnetic separator is balanced in weight
balancing machine. From this machine they know the amount of barley bought without unusable
substances from the market in to the factory. This machine works by using pneumatic valve. It is
controlled or programmed by computer. It could weigh up to 400kg of barley in once. It’s a
pneumatic system which works by opening the upper and bottom part. When barley that weighs
436kg is in the balancing machine the upper parts closes and the bottom part is opened.

Then the balanced barley moves to the bin and after the machine is empty the bottom part is
closed and the upper part opens until 400 kg barley is in the balancing machine. By this cycle
barley is balanced in the in great amounts.

Figure 2. 7 weight balancing machine

8. Storage component: The storage components

are bin and silo.

a. Bin
The bin is used as a storage. The barley that is graded is stored according to its level separately
and the bins capacity differs for different level; for level one and two the bin can store up to 50t

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and for the third level the bins can carry up to 35m 3 of grain. This storage unit is also used for
storing dust from the cyclone with capacity of 20m3.

b. Silo
It is used as a long tern storage unit and each silo has the capacity of up to 10,000quintals.
Before the barley or malt enters the silo a chemical photoxin is used for protection against
insects. The silo is made of steel metal sheet to prevent the corrosion.

Figure 2. 8 silo
9. Grain cooler
Grain cooler is a popular grain storage tool that increases marketing opportunities by insuring
better control of grain quality during storage I the silo blowing cold air in the silo via perforated
floor. Grain cooler has four main purposes;

 preventing mold,
 inhibiting insect development,
 maintaining seed viability and
 Reducing grain moisture.
Without grain cooler grain is an effective insulator and will maintain its warm harvest
temperature for a long time. So during storage it must be cooled by grain cooler machine. The
grain cooler has a compressor which is used to blow the air to silo and it uses its refrigerant.

10. Screening and grading machine

The barley that comes from the storage or from the balanced is sized in to different way. Grading
of barley in to different sizes of grain is useful, so that it will be evenly processed in the
germination, steeping and kilning processes for the same batch.
Working principle

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It has three different sizes of plates called sieves, which have different sizes and allow the barley
through depending on its thickness. The machine is vibrated in motion because of unbalanced
pulley in its system, so as the motor rotates the machine vibrates.
And this machine grades barley into three different levels. The first two levels which have a
thickness of are used in the processes to come to produce malt whereas the third level barley is
sallied as a byproduct to farmers.

2.3 Components of grading machine

 Screw
 Flaps -used to separate dust from barely
 Motor -used to drive the unbalanced pulley in turn vibrating the machine.
 Air duct -is a duct that used to transport the dust which is sucked by cyclones
 Rubber ball -used to ensure the availability of maximum holes at any time for proper
grading by cleaning the sieves.
 Unbalanced pulley
 Sieves- device used to separate malt barley from other larger substances and also used to
separate larger grains from smaller once. It has three different sizes.
First grade barley >2.5mm
Second grade barley from 2.2mm up to 2.5mm.
Third grade barley <2.2mm
The first two grade barleys are used in the malt production. The third grade barley not used in
the production of malt; they sold in the market.

Figure 2. 9 grading machine

11. Drum sieve
The grain malt which will be going to dispatch that comes from the silo must be cleaned in this
machine. Working principles of Drum sieve machine is Because of the pneumatic system the

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machine gain high vibration motion. During the vibration the sieve in this machine grade the
grain malt. The barley grain which have large size drop out from the sieve. The medium size
grain malt move to the dispatch machine and the dust particles with small size grain malt suck by
the cyclone machine.

12. Weighting
The barley that is graded by the grading machine which graded in to three groups is balanced in
weight machine. From this machine they know the amount of which is graded into three group.
This machine works by using pneumatic valve. Working principles of balancing machine. It is
controlled or programmed by computer. It’s a pneumatic system which works by opening the
upper and bottom part.
2.3 Steeping

Steeping is the start of the active malting process. Steep water is added to cover the grain and the
grain moisture content increases. Is the process of immersing the cleaned barley ready for
malting, is washed and steeped to raise the moisture content in the barley so that the enzymes are
activated to enhance germination processes. Grains that are float, do not germinate due to their
size are skimmed in the process. This process is usually takes for two days. The required
moisture that could facilitate germination is achieved within the period. Water pumps are the
main operational devices in which it allows the water and moisture. The water

1. Steeping tank
Steeping tank is made up of steel and used for store and washing barley that is ready for malt and
moist the barley. It has slider at the top of the tank which is used for taking out the floating
material from the steeped barley.
 Has cylindrical shape which is open at the top and consists of tubes at the bottom.
 There are six steeping tanks in number. Among these four tanks are old versions while
the left are new steeping tanks.
 The old steeping tank has capacity to takes up to 690 for each while the new steeping
tank has capacity to take up to 750 quintals for each.
 To resist corrosiveness, the internal part must be painted.

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Figure 2. 10 steeping tank

In the steeping step oxygen is quickly taken by the grain and the water becomes de oxygenated
the carbon dioxide content increases. The aim of steeping is to supply grain with proper quantity
of water to develop malt sprout and rootlet, to initiate enzymatic activity and to accelerate its
biochemical metabolism.

2. Carbon dioxide extraction fan

CO2 extraction fan is used to suck the carbon dioxide from the steeping tank because during the
steeping process the water makes moist and hot, at this carbon dioxide is produced. So this
carbon dioxide is removed or sucked out from the steeping tank by this carbon dioxide extraction
fan. The CO2 is sucked out of the tank through the motor.

Figure 2. 11 Carbon dioxide extraction fan

3. Aeration fan (blower)
Blowers or aeration fan is used to compress the air by taking from the surrounding atmosphere.
This compressed air used for washing and aeration purpose. The air is supplied through the
bottom of tank. The air used to clean barley properly and make efficient carbon dioxide sucking
processes.

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Figure 2. 12 aeration fan

4. Water pump
 It is used to pump water to steeping tank.

Figure 2. 13 Water pump

5. Spray pump
 It is used to spread water in steeping tank from water pump

6. Distributor
 It is steel metal that has conical shape.
 Used to distribute barley equally in the steeping tank.

Figure 2. 14 distributor

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7. Discharge pump
It is used to pump or push steeped and moist barley to the germination box with help of water
pump; the water pump creates an increase in pressure by transferring mechanical energy from the
motor to the fluid through the rotating impeller. The water flows from the inlet to the impeller
Centre and out along its blades. The centrifugal force here by increases the fluid velocity and
consequently also the kinetic energy is transformed to pressure.

2.4 Hydraulic components

The principles of the hydraulic components are common for most centrifugal pumps. The
hydraulic components are the parts in contact with the fluid. It consists;
 Impeller; the blades of the rotating impeller transfer energy to the fluid there by
increasing pressure and velocity. The fluid is sucked into the impeller at the impeller eye
and flows through the impeller channels formed by the blades between the shroud and
hub,
 Impeller seal; a leak flow will occur in the gap between the rotating impeller and
stationary Pump housing when the pump is operating. So in order to reduce the linkage
between them is mechanical is used.
 Volute casing; the volute casing collects the fluid from the impeller and leads to flange.

CHAPTER 3

GERMINATION ROOM (WET STATE)

3.1 Germination process

The moist content or steeped barley is pumped over to the germination box, and then germinates
in which the starch in the barley changes to fermentable sugar. The process of germination tasks
is not easy process because it is not unique process and it needs understanding of machine and
science that used for germination process such as cooling system, turning effect and etc. from
different angles.
This process takes four and half days to five days depending on the size of barley; small size
grains usually germinate faster than large size grains.
Germination controlled by;
 Drawing temperature

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 Adjusted humidified air through the bed.

The barley in germination room passes through different systems. These are:
 Hydraulic system
 Pneumatic system
 Electric system
 Mechanical system and
 Air conditioning system
The barley comes to germination box from steep tank by means of discharging pump.

1. Hydraulic system
Hydraulic system requires the following components.
 Reservoir,
 Hydraulic Pump,
 Electric motor,
 Solenoid valves,
 Actuators,
 Fluid transfer piping (Hose),
 Pressure gauge,
 Pressure regulator levels,
 Hydraulic cylinder,
 Hydraulic shovel piston Hydraulic pump.
Hydraulic pump is a device which converts mechanical energy into hydraulic energy. The pump
is used to impart motion to a liquid. It provides the force required to transmit power and motion.
It produces only fluid flow but does not produce pressure. A hydraulic pump with three pressure
connections is available for lifting and lowering the discharging shovel and also for the coupling
and uncoupling of the lower unit. This hydraulic pump collection is driven by means of a three
phase current short circuited motor. The hydraulic oil is topped up before start up.

A. Electric motor
The powered electric motor (dc motor) converts the electrical energy into mechanical energy
which is used to drive the shaft, belt, coupling, pinion gear. The pump in turn converts the
mechanical energy into hydraulic energy

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B. Reservoir (tank)
Reservoir or tank is a device in which the oil or fluid requires for the process is added. Also the
oil after the process enters into this device.

C. Valves (solenoid valves)

Valves control the amount of oil transferred through each process. It is an electromechanically
operated valve.
This valve is controlled by electric current through a solenoid. In case of two part valve the flow
is switched on or off. But in three port valve the out flow is switched between the two outlet
ports.
D. Non return valve
This valve allows the oil to flow only in forward direction.

E. Pressure limiting valve

This valve controls the overflow of pressure through the process.

F. Pressure gauge
It measures the amount of pressure passes in system.

G. Hose

It is flexible hollow tube which is designed to carry the oil or fluid from one place to another.

H. Throttle non return valve

It controls the amount of oil that flows into double action hoisting cylinder.
Working principle
The oil in reservoir is pumped by using dc motor. The pump has three discharges tube. One
discharge tube is for double action hoisting cylinder for connecting and disengaging the lower
chassis and the other two discharges is for double action hoisting cylinder for blade.
The mechanism is as follows:
For first discharge tube, when the oil is pumped it passes through 4/3 solenoid valve by allowing
the valve to open and then flow through non return valve to throttle non return valve. At this
condition, the oil pushes up the piston to engage double action hoisting cylinder from the lower
chassis. But when the piston is pulled down, the double action hoisting cylinder is disengaging
with the lower chassis. After this process, the oil is returned back to the reservoir. These actions

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are done simultaneously to connect or disengage the double action cylinder with the lower.
The other two discharges are for hoisting cylinder for blade. As the above, the oil is pumped
through the second and third discharge and flows to nun returning valve through 4/3 solenoid
valve by allowing it open. Then when the piston moves down it increases the length of shovel
and simple to collect the green malt. But when the piston moves up the shovel also stands up.
Finally, the oil after the system returns back to the reservoir. This process is the same and
simultaneous for both second and third discharge tube.
Under the process, there is pressure limiting valve for each discharge tube and pressure gauge
after non return valve. In hoisting cylinder for blade also uses pressure valve while in hoisting
cylinder to connect or disengage the lower chassis also it uses throttle non return valve. In this
system, also the oil passes the solenoid through the inlet valve while leaves throughout ports or
valve.

2. Electric system
Motor is used to rotate the screw turner. In case of automatic germination box every screw turner
have their own motor. Sensor is used to motion of worm turner; it controls the motion of the
worm turner. The turning process is done according the command that the laboratory tarnation
give to workers the same is true for water sprays; this means it is controlled by computer
program. Usually turning is done with in the 18 hours. The use of worm turner is used to level
the grain and take out green malt from the germinating box; in this case the screw pulls the
barley to take out.

Figure 3. 1 new germination box

There two germination rooms

 new germination room and

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 old germination room

3. New germination room
It is called new germination room because it constructed during the second expansion of the
factory. It consists;

a. Germinating box
These germinating boxes are made up of concrete, and a rectangular which is perforated floor
which is made up of sieve. It is used to store germinating barley or malt up to time, to complete
germinating process. It holds one batch at a time.

b. Worm turner
It is a machine that is used to turn the malt or germinating barley to prevent the tightening of
malt barleys, or attaching of malts to each other. It is a machine that turns the malt by moving
forward and backwards by using mechanical and electrical system. It levels the barley
transported from the discharge pump.

Worm turner used in the new germination box is also used to draw back the green malt from the
box. The worm turner is essential in the productivity of the factory.

3. Mechanical systems

A. Screw turner- which is used to turn the malts by rotating with the help of energy that get from
the electrical motor.

B. Gear-It is the spur gear which is meshed to each other to rotate the screw turner. It transmits
the rotational energy that from motor through pinion gear.

C. Coupling-it is used to join the motor to the pinion gear, so the motor used to rotate the gear
that is meshed to each other through the pinion gear.
Electrical system

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D. Motor-is used to rotate the screw turner, means every screw turner have their own motor.
E. Sensor-is used to motion of worm turner, it controls the motion of the worm turner.

4. Old germinating room

It called old germinating room because it is Constructed during the factory is constructed and it
uses the old machines to turn the green malt, so why it is called old germination room.

a. Worm turner; It is a machine that is used to turn the malt or germinating barley to prevent the
tightening of malt barleys, or attaching of malts to each other. It is a machine that turns the malt
by moving forward and backwards by using mechanical and electrical system.

b. Gear; it is the spur gear which is meshed to each other to rotate the screw turner. It transmits
the rotational energy that from motor through pinion gear.

c. Shovel-is made up of steel, which is used to level the barley and take out the green malts from
the germinating box.
The difference between the old germination room and the new germination rooms are:
 The new germination screw turners have their own motor, consequently can work at
different speed or times; all screw turners can work at different revolution. But old
germination room has a pinion which moves all the screw turners by the mesh between
the gears on both sides.

 Old germination room has the shovel to removes the green malt from the box; while the
screw turners used to remove the green malt from the box in the new one.
3.2 Cooling process

3.2.1 Radiator
Radiators are used to convert thermal energy from one mode to another for the purpose of
cooling and heating. It act as the coolant source in automatic engine cooling, building and etc.
Radiators components include;
Upper tank: due to absorbing heat from engine coolant get hot, the liquid expands. The pressure
causes the coolant to get higher than the pressure cap, in order to prevent leakage excess coolant
is needed.

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Lower tank: bottom tank receives the cooling water just after it had pass through the heat
radiating tubes and fins in the body of the radiator.
Tubes: as the coolant passes through the radiator tubes on its way to the opposite tank, it transfer
heat to the tubes that transfer heat to the fins that are attached between the rows. The fins head
the heat flow to the ambient air. Radiators are made of brass.
Filler cap: coolant is press in the tank that will increase the pressure in the tank. Coolant begin to
expand consequently, coolant temperature leads to an increase in pressure in the cooling system.
Pressure relief valve in the filler cap opens. It allows air to escape. Partial vacuum forms in the
cooling system when coolant temperature returns to normal.
Fins: fins are surfaces that are used to increase the rate of heat transfer to or from the
environment and they extend from the surfaces by increasing convection. Fins increase the
surface area and can be an economical solution to heat transfer problems.
Radiator working principle
Radiator has both tanks on both sides and there is a transmission cooler inside the tank. Radiator
has aluminum mesh, aluminum ports have two port inlet and outlet ports. There are tubes
mounted in the parallel arrangement inside the radiator and aluminum fins are attached to all of
the tubes.
In the radiator, coolant flows from the inlet to the outlet through many tubes mounted in the
parallel arrangement. The hot water enters radiator through inlet port.

A fan is attached behind the radiator to cool down the hot water in the tubes. The fan blows the
air and cools down the water. So the water is going to come out cooler than it enters before and
then go back.
Radiator advantage
 good heat dissipation
 good performance of oxidation corrosion resistance
 highly responsive
 less polluting
Disadvantage
 heat loss takes place if not used and maintained properly
 noisy operation

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 Needs adequate amount of airflow in the room in order for a radiator to properly work.
 Radiators can grow extremely hot to the touch while working.

3.2.2 Compressors
A compressor is the most important and often the costliest component (typically 30 to 40 percent
of total cost) of any vapor compression refrigeration system (VCRS). The function of a
compressor in a VCRS is to continuously draw the refrigerant vapor from the evaporator, so that
a low pressure and low temperature can be maintained in the evaporator at which the refrigerant
can boil extracting heat from the refrigerated space. The compressor then has to raise the
pressure of the refrigerant to a level at which it can condense by rejecting heat to the cooling
medium in the condenser.
The purpose of compressor (gas or liquid) is to increase the pressure of a fluid by putting in shaft
work (power, on a rate basis). There are two fundamentally different classes of compressors. The
most common is a rotary-type compressor (either axial flow or radial/centrifugal flow), in which
the internal processes are essentially the opposite of the two processes occurring inside a turbine.
The working fluid enters the compressor at low pressure, moving into a set of rotating blades,
from which it exits at high velocity, a result of the shaft work input to the fluid. The fluid then
passes through a diffuser section, in which it is decelerated in a manner that results in a pressure
increase. The fluid then exits the compressor at high pressure.

Heat rejection from the working fluid during compression would be desirable, but it is usually
small in a rotary compressor, which is a high-volume flow-rate machine, and there is not
sufficient time to transfer much heat from the working fluid. In a piston/cylinder-type
compressor, the cylinder usually contains fins to promote heat rejection during compression (or
the cylinder may be water-jacketed in a large compressor for even greater cooling rates). In this
type of compressor, the heat transfer from the working fluid is significant.
Advantages of compressor
 Low service cost
 Mobile
 Simple control system
 More reliable

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Disadvantage of compressor
 Low capacity
 Relatively expensive
 When scroll element fail, most probably you must have to buy a whole new element
 The compressed air gets very hot
 High noise operation
 Low efficiency approximately 65-70 %
Cooling plant is used to produce cooling ammonia in the cooling tank. This cooled ammonia is
used to control the temperature in the germinating room. Firstly, ammonia in the form of gas is
added to ammonia tanker with expander and pipe line. Second ammonia is sucked by the
compressor and compressed next ammonia is discharged to the condenser and expansion valve.
Then given to the germinating room through the insulated pipe.
Ammonia is compound of nitrogen and hydrogen with the formula NH 3 it is colorless gas with a
Charest pungent smell. Ammonia contributes significantly to the nutritional needs of territorial
organisms by serving a precursor to food and fertilizers. NH 3 boils at -33.34 0C at a pressure of
one atmosphere, so the liquid must be stored under high pressure or at low temperature. So
cooled ammonia that transported to radiator is cools the radiator body.
More than 130 million tons of ammonia are produced around the world every year and counting.

NH3 is one of the most widely produced chemicals and at the same time one of the most widely
used hazardous substantial in industrial sector. The several reason for this are:-
1. Risk of explosion and fire: ammonia is a flammable gas and can form flammable or
potentially explosive compounds in a dry air when in gaseous state. Ammonia is
generally lighter than air and reaches the atmosphere with a high diffusion velocity. It has
high affinity for moisture and quickly forms compound with the moisture in the
atmosphere. If ammonia leakage occurs water curtain are used to damp down vaporous
ammonia. The gas then sinks to the ground in the form of ammonia aerosol visible as a
white mist.
2. Toxicological danger: ammonia is a respiratory poison that has a strong irritating and
corrosive effect in gaseous state but mainly in liquid state. Symptoms of ammonia

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include suffocation, breathing difficulty, and dizziness, burning sensation in the throat
increased salivation stomach ache and vomiting. Further can cause blindness.
Using ammonia for refrigeration is effective, saves resources and is safe. Unpredicted gas leaks,
however cannot be completely prevented. A modern gas detection system reduces the risk of
production downtime, protects the employee health and can save seconds that make a difference
in case of an alarm.
Ammonia has a very good volumetric cooling capacity and is a very effective refrigerant due to a
heat of vaporization of 1368 kJ/kg. Only small amount of ammonia needs to be moved in the
system. Approximately 13 to 15 percent compared to fluorocarbons, to generate a high
refrigeration capacity. It is generally cheap than other cooling gases. Additionally Freon gases;
which is a manmade refrigerant that was developed as an alternative to both Sulphur dioxide and
ammonia; is used. Freon gases is less efficient than ammonia. Hence ammonia is widely used
refrigerant.
Advantages of ammonia over other gases
 Effective
 Environmentally compatible
 It’s global warming potential (GWP) and ozone depletion potential (ODP) equals zero.
 Good volumetric cooling capacity
 Excellent thermodynamic properties

Disadvantages of ammonia using as a refrigerant

 Not compatible with copper
 Poisonous in a high concentration
3.3 Cooling system

It is used to control the temperature of the green malts in the germinating box. It consists of;
 Spray water- is used to pump water in front of radiator.
 Radial fan- it is centrifugal flow fan moves air that is perpendicular to the axis of rotation
to the germinating box through the parts of the radiator, and spray of water.
3.3.1 Working principles of cooling system
Ammonia that comes from the ammonia tanker is circulates in side of very tinny pipe, inside the
parts of the radiator. So from this tinny pipe of ammonia, the cooling is transferred to these parts

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of the radiator, this means the parts of radiator is cooled. So the radial fan that moves air in to the
germinating box, through the radiator and spray water is cooled inside the parts of the radiator
and passed with water to germinating box. In this case the cooling of the germinating box is
controlled.

NH3 Tank NH3 compressor Oil separator

Start
And gauge

NH3 return Heat exchanger

line

Germination box Surge tank

Valve gauge

Axial fan Valves and

NH3 evaporator gauge NH3 pump

Figure 3. 2 ammonia recycle and processes

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CHAPTER 4

KILNING PROCESS (DRY STATE)

4.1 Kilning process

Kilning in which the germination of the grain terminates by drying the germinated barley, green
malt is the final production process in malting. In the kilning process the moisture in the green
malt is reduced with the kilning period of 17-19 hour which is depending on the grain size of
barley. Enzymes activities terminate and the malt will have the flavor, taste, and color in the end
of process.
The working principles of kiln process using central suspension loading and unloading machine
green malt from green malt chain conveyor is poured into the sieve of kilning room. The steam
that is pumped by steam pump comes from the boiler with insulated covered pipe is a given to
the heat exchanger or radiator with heating system and valves, next given to the malt using high
power pump. The heat exchange process in the radiator is hot air or steam circulates across the
radiator and the hot air losses its heat and it becomes colds (water) then return to the boiler.
There are two types of tubes in radiator. Which suck out cooling air (liquid water) from the
radiator and the other is steam comes from the boiler high power fan blowers hot air from the
part of the radiator the malt through the sieve. This process takes 17 to 19 hour.

4.1.1 Classes of kilning room

Depending on the duration of construction and working principle of machine they use, the kiln
room is divided in to two types;
 New kiln room and
 Old kiln room

A. New kilning room

Is constructed during the expansion of factory. New kilning room tank or box is circular shape
and in order to level the green malt is used rotating screw and also in order to take out dry from
the box it use this screw.

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B. Old kilning room

It is constructed during the construction of the factory. So why it is called old kilning room, it is
rectangular shapes and uses shovel to take out dry malt from the kilning box and also use shovel
to level green malt in the kiln box.
Reversible tabular screw conveyor takes the green malts to the new and old kilning room. When
it is needed to take to the new kiln room the motor rotates clock wise and for the old kiln room
the screw rotates clock wise direction.
Kilning objective
 Stop germination
 kill embryo
 Reduce moisture of malt
 Dry the rootlets to permit their removal
 Development aroma and color
 Preserve enzyme
 Remove undesirable flavors and enzyme
 Antioxidant Potential
4.2 Boiler

Also known as steam boiler. It is a closed vessel in which fluid (typically water) is heated. It is
called steam generator, which is a device used to produce steam by applying heat energy to the
water. Boiler is essential part of thermal power plant. There are many types of boiler. We
observed in the Asella Malt Factory two types of boiler those are;

4.2.1 Furnace tanker

Furnace tanker is used to fuel that is used as a source for boiler. It has pre-heat or to reduce
viscosity of fuels by using heavy heat pump and to facilitate the transportation of fuel across the
pipe, at the same time furnace tankers have filter tank. It also has a sensor that makes alarm when
the fuel that is inters in to the tank is full. So it reduces the over flow of fuels from the tanker.

Working principle
The basic working principle of boiler is that a boiler is closed vessel inside which water is stored.
Fuel (mainly coal) is burnt in a furnace and hot gasses are produced.

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A boiler incorporates a fire box or furnace in order to burn the fuel and generate heat. These hot
gasses come in contact with water vessel where the heat of these gasses transfer to the water and
consequently steam is produced. The generated heat is transferred to water to make steam, the
process of boiling. This produced saturated steam at a rate which can vary according to the
pressure above the boiling water. Then higher furnaces temperature, the faster steam production.
A fire box surrounded by water space and a boiler barrel consists of two telescopic rings inside
which were copper tubes mounted. The tube bundle occupied much of the water space in the
barrel and vastly improved heat transfer. The percentage of total heat exported by outlet steam in
the total heat supplied by the fuel is called steam boiler efficiency.
4.2.2. Components of boiler
A. Combustion chamber
The source of heat for a boiler is combustion of fuels and natural gas. In an electric boiler the
source of heat is electric resistors. So in order to optimum burning the characteristics of the fire
air needs to be supplied.
B. Combustion air blower
The air fan is designed and provided by the boiler manufacturer and is integral with the boiler
housing. An important characteristic of blower is the ability to maintain relatively constant air
pressure over a wide range of airflows.
C. Flue
Flues are a boiler firebox exhaust duct or boiler discharge stack, it must be large enough to
conduct the products of combustion away from the boiler with the minimum of duct friction
losses. Carbon steel and stainless steel are common materials associated with packaged boiler
installations.
D. Economizer
Economizers are an energy recovery devices that uses the hot exhaust gases from the boiler. That
is waste water to heat combustion air or feed water.
E. Steam traps
Steam traps are installed throughout steam systems to remove condensate. The condensate
includes spent steam, air and non-condensable gases from the steam system.
F. Piping
Used in steam and hot water systems.

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G. Fire tube boiler

Fire tube boilers have been one of the predominate boiler designs for well over a century and
even today they represent a majority of the high pressure steam generating capacity for units in
the normal size range and not all fire tubes boilers are created the same times. The flue gas
turnaround from the furnace to the second pass tubes can be done in two common methods, a
wetback and dry back turnaround.
Wetback boilers have a water cooled chamber located in the vessel for the furnace turnaround
and although it doesn’t require regular maintenance, it is difficult to access for inspection,
maintenance and repairs. The dry back boiler has the furnace turnaround in a separate refractory
chamber attached to the back of the vessel, making vessel access very easy, but it can require
more regular maintenance of the gaskets and refractory.
One weakness of a multi-pass Fire tube boiler is a problem called “Thermal Shock”. This is
actually not a shock, but a difference in thermal expansion and contraction caused by the furnace,
tubes and shell heating and expanding at different rates, causing high stresses and fatigue failure.
This is prevented by performing a slower warmup cycle to minimize the temperature differences.
A similar problem occurs with hot water applications, where sudden changes in the water
(return) temperature cause different expansions and contractions.
In fact, multi-pass Fire tube boilers are not usually used for hot water applications today because
of this issue.
The next stage in the process is to boil water and make steam. The goal is to make heat flow as
completely as possible from the heat source to the water. The water is confined in restricted
space heated by the fire. The steam produced has been less dense than water and therefore will
accumulate at the highest level in the vessel its temperature will remain at boiling point and will
only increase as the pressure increases. The steam n equilibrium with the liquid water which is
being evaporated within the boiler is named saturated steam. By continuous heating of saturated
steam will bring the steam to a supper heated state, where the system is heated to a temperature
above the saturation temperature and no liquid water can exist under this condition.
Fire tube boiler components contains;
H. Firebox: where the burners are located and radiant heat transfer occurs.

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I. A special refractory lining (a bricklike form of insulation): is used to reflect heat

back into the box and protect the structural steel in the boiler. Firebox the area of
a boiler where the burners are located and where radiant heat transfer occurs.
Refractory lining a bricklike form of insulation used to reflect heat back into the
box and protect the structural steel in the boiler. Located in the firebox area of the
boiler are radiant tubes.
J. Radiant tubes and riser: tubes both contain boiler feed water that is heated by
radiant heat from the burners and boiled to form steam that is returned to the
steam drum.
K. Burners are devices that introduce, distribute, mix, and burn a fuel (e.g., natural
gas,
fuel oil, or coal) for heat.
L. Pilots are used to light burners. A burner can be a premix burner (fuel gas and air
mixed before either enters the burner tip), a raw gas burner (gas not premixed
with air), or a combination.
M. Air registers control the flow of air to the burners to maintain the correct fuel-to-
air ratio and to reduce smoke, soot, or NOx (nitrogen oxide) and CO (carbon
monoxide) formation.
Draft fan is used to control draft in a boiler. Depending on the design of the
boiler, the draft fan either forces the air through the boiler (forced draft) or pulls
the air through the boiler (induced draft). In some boilers, a combination of the
two is used (balanced draft). Water tube boilers have a stack at the top of the
boiler to remove flue gas. Contained within the stack is a damper for regulating
the flow of flue gases. A steam drum at the top of the boiler is where all generated
steam gathers before exiting the boiler. Depending on the boiler design, water
enters the steam drum or the mud drum from the economizer. At the bottom of the
boiler is the mud drum, where sediment accumulates. This sediment is removed
by intermittent blowdown, which is done manually.
N. Down comers: are tubes that transfer water from the steam drum to the mud
drum.

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O. As cooler water descends from the steam drum and flows through the down
comers, it picks up heat from the firebox and replenishes the water supply to the
mud drum.
P. Riser tubes: allow water or steam from the lower drum to move to the upper
drum.
Q. Super heater: is a set of tubes located toward the boiler outlet that increases
(superheats) the temperature of the steam flow. The steam drum usually is
connected to the super heater through a coil or pipe.
R. Desuper heater: is a temperature control point at the outlet of the boiler steam
flow that maintains a specific steam temperature by using boiler feed water
injection through a control valve. The purpose of the Desuper heater is to lower
the temperature of the steam.
Advantage of furnace boiler
 quite compact in construction
 fluctuation of steam demand can be met easily
 quite cheap
Disadvantage of furnace boiler
 As the water required for operation of boiler is quite large, it requires long time for rising
steam at desired pressure.
 As the water and steam are in same vessel the very high pressure of steam is not possible.
 The steam received from fire tube boiler is not very dry
 Less efficient compared to electrical boiler

Figure 4. 1 furnace boiler

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4.2.3 Electrical boiler

Electric boilers are not usually used in large heating systems but are sometimes found in smaller
heating systems. They are often used in hospitals, schools, hotels, etc., to provide steam for
heating, sterilizing, laundry equipment, and kitchen equipment. Another application is in a
system where electricity, produced by a gas turbine driving a generator, is used in an electric
boiler to produce steam which supplements steam produced in a waste heat boiler. The waste
heat boiler uses the gas turbine exhaust as a heat source.

Figure 4. 2 electric boiler

Components of electrical boiler include:

 Boiler shell
 Combustion shell
 Grate
 Furnace
 Heating surface
 Mountings
 Accessories (Thermoregulation valve, Steam pressure reducer valve, Y filter, Reducer,
By pass and steam globe valve, Pressure indicator, Pressure indicator, Auxiliary valve)

Advantages of Electric Boilers:

 Electric boilers are very compact as they do not require furnace space for combustion,
and therefore do not require ductwork or a chimney.
 No fuel storage space is required as in the case of oil-fired or coal-fired boilers.

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 Electric boilers are quickly and easily installed due to the fact that ductwork, chimneys,
and fuel lines are not required.
 A high percentage (98%) of the energy delivered by the electricity is absorbed as heat in
the boiler.
 Electric boilers produce no pollution such as smoke, dust, ashes, etc.
 Electric boilers are silent in operation
 Safe because there is no possibility of furnace explosion.

Disadvantage of Electric boilers:

 High comparative cost of the electricity required.

 Due to the effect of high temperature on the electrodes (elements) most designs are
limited in pressure to near about 2100 KPa.
 If there is lack of electricity the service is null.
 Highly damaged if there is cable hazard

Figure 4. 3 components of electric boiler [5]

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4.3 Boiler water treatment

The water supplied to the boiler that is converted into steam is called feed water. The two
sources of feed water are condensate or condensed steam returned from the processes and
Makeup water (treated raw water) which must come from outside the boiler room and plant
processes. There are two types of boiler water treatment.
Water treatment is used to remove suspended solids, dissolved solids (particularly the calcium
and magnesium ions which are a major cause of scale formation) and dissolved gases (oxygen
and carbon dioxide).

The water treatment processes available are:

 Ion exchange
 Demineralization
 Reverse osmosis and
 De-aeration.

Before any of these are used, it is necessary to remove suspended solids and color from the raw
water, because these may foul the resins used in the subsequent treatment sections. Methods of
pre-treatment include simple sedimentation in settling tanks or settling in clarifiers with aid of
coagulants and flocculants. Pressure sand filters, with spray aeration to remove carbon dioxide
and iron, may be used to remove metal salts from bore well water. The first stage of treatment is
to remove hardness salts and possibly non-hardness salts. Removal of only hardness salts is
called softening, while total removal of salts from solution is called demineralization.

The processes are:

a. Ion-exchange process (Softener Plant).

In ion-exchange process, the hardness is removed as the water passes through bed of natural
zeolite or synthetic resin and without the formation of any precipitate. The simplest type is ‘base
exchange’ in which calcium and magnesium ions are exchanged for sodium ions. After saturation
regeneration is done with sodium chloride. The sodium salts being soluble, do not form scales in
boilers.

Softening reaction:

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Na2R + Ca (HCO3)2 Ca R + 2Na (HCO3)

Since base exchanger only replaces the calcium and magnesium with sodium, it does not reduce
the TDS content, and blowdown quantity. It also does not reduce the alkalinity.

Figure 4. 4 water treatment

b. Demineralization
Demineralization is the complete removal of all salts. This is achieved by using a “cation” resin,
which exchanges the cations in the raw water with hydrogen ions, producing hydrochloric,
sulphuric and carbonic acid. Carbonic acid is removed in degassing tower in which air is blown
through the acid water. Following this, the water passes through an “anion” resin which
exchanges anions with the mineral acid (e.g. sulphuric acid) and forms water. Regeneration of
cations and anions is necessary at intervals using, typically, mineral acid and caustic soda
respectively. The complete removal of silica can be achieved by correct choice of
anion resin.
c. Reverse osmosis
Reverse osmosis uses the fact that when solutions of differing concentrations are separated by a
semi-permeable membrane, water from less concentrated solution passes through the membrane
to dilute the liquid of high concentration. If the solution of high concentration is pressurized, the
process is reversed and the water from the solution of high concentration flows to the weaker
solution.

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This is known as reverse osmosis. The quality of water produced depends upon the concentration
of the solution on the high-pressure side and pressure differential across the membrane. This
process is suitable for waters with very high TDS, such as sea water.
d. De-aeration
In de-aeration, dissolved gases, such as oxygen and carbon dioxide, are expelled by preheating
the feed water before it enters the boiler. All natural waters contain dissolved gases in solution.
Certain gases, such as carbon dioxide and oxygen, greatly increase corrosion. When heated in
boiler systems, carbon dioxide (CO2) and oxygen (O2) are released as gases and combine with
water (H2O) to form carbonic acid, (H2CO3). Removal of oxygen, carbon dioxide and other non-
condensable gases from boiler feed water is vital to boiler equipment longevity as well as safety
of operation. Carbonic acid corrodes metal reducing the life of equipment and piping. It also
dissolves iron (Fe) which when returned to the boiler precipitates and causes scaling on the
boiler and tubes. This scale not only contributes to reducing the life of the equipment but also
increases the amount of energy needed to achieve heat transfer. De-aeration can be done by
mechanical de-aeration, by chemical de-deration or by both together. In boiler systems, steam is
preferred for de-aeration because:
 Steam is essentially free from O2 and CO2
 Steam is readily available
 Steam adds the heat required to complete the reaction.

To treat correctly the feed water is compulsory for the good working of steam boilers. Producing
quality steam on demand depends on properly managed water treatment to control steam purity,
deposits and corrosion. Boiler is sump of its system. It ultimately receives all of the pre boiler
contaminants. Boiler efficiency, performance, service life, are direct products of selecting and
controlling feed water used in the boiler. To grant long life to boiler the following needed.

a. Water softeners: automatic volumetric softeners with exchange of bases. Vinyl ester resin
container cylinder, salt storage tank with level control, bronze enbloc valve with
incorporated automatic by mass for the regeneration, back wash and running operations.
b. Metering pumps: injects the conditioning liquid into the water and condensate liquids.
The conditioning liquid prevent the formation of scales and protect the material surfaces.

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The metering pumps are of the simple and strong construction and they does not require
any maintenance and are designed for continuous service even under the hardest
operating conditions.
c. Demineralizers: Demineralizers are used to work on the complete removal of all salts.
d. Filters: the process of removing particles from water or some other fluid by
passing it through porous media. Removal of coarse suspended matter and sludge from
coagulation or from water softening systems. Gravel beds and anthracite coal are
common materials used for filter beds.
e. Deaerators: provide simple and effective removal diluted gases in the water. To prevent
the corrosion in the thermal circuit the separation and removal of dilutes gases in the
steam generator feed waters must be fully recovered. Deaerator body composed of;
 Cylindrical horizontal tank manufactured with carbon steel plate
 Manhole and head hole
 Flanged nozzles
 Saddles
4.4 Polishing machine
The rootlet removal screw basically consists of Rotor, Worm gear motor, an outlet box, closed
trough. The germinated and kilned malt reaches the trough through an inlet spout being equipped
with an air feed throttle valve. The adjustable ripped paddle conveys the malt towards the outlet
box; during this process, the rootlets are separated from malt kernels due to the intensive whirl
movements. In the outlet box, and the rootlets drop through the grid-type bottom into the product
outlet hopper. The cleaned malt is stored in silos to be blended with pieces to produce larger
homogenous batches of malt.

In order to separate the rootlets, a downstream air classifier or a sieving machine must be
installed. Lumps that may have formed are conveyed by means of the dischargers onto the
grating, collected in the lump outlet and eliminated through the rubber valve. Above the grating,
there is an exhaust spout trough which dust and fines can be discharged.

Finally, the malt is cleaned prior to sale using sieves and aspiration to remove the dust, lumps
and stones in the malt. Magnets are again used to remove any steel that might damage the mill
rollers.

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The trough covers screwed on top are equipped with sight glasses for function control for safety
purposes; a back-up detector is fixed above the outlet. A lockable flap allows immediate access
to the outlet.

This machine contains teeth like screw attached by angles on the shaft in the pipe. For the
rotation of this screw motor is used as prime mover. The machine has two functions:
 Remove rootlets from malt
 Moves malt to the next step that is to aspiration channel.

4.5 Cyclone
It is a machine used to remove the majority of dust particles from the barley with air. The dust
filled air is introduced to the cyclone chamber via an inlet mounted tangentially to the cylinder at
the top. This causes the air and dust to circulate around the outside of the container, and such
centrifugal forces keep the particulate matter to the outside edges separating the dust into a
separate holding chamber, where the air is relatively still and dust can settle.

Figure 4. 5 cyclone

4.6 Dispatching machine

It is the end process of the malt in which the grain malt that comes from the silo is balanced and
sealed. It balanced 50 kg per sack and employees manually take the sack in to the belt conveyor
and then to the carriage, where it will be transported to the breweries.
4.7 Belt Conveyors
They are suitable for handling many materials in a wide range of sizes, over long distances up
and down slopes. They are outstanding for low power requirements, high capacities, simplicity

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and dependable operation. Material is carried on belt running over anti-friction idler rolls.
Horizontal belt at dispatch has a capacity to transport four up to six bags. In case the bags are
over the capacity of the belt conveyor it automatically stops.
Component of Belt Conveyors:
Drum: transmitting power from the motor to the driving pulley or pulleys
Take-ups: Every belt conveyor must be equipped with a take-up.

Belt: used to convey the bags.

Motor: convert electrical energy to mechanical energy

Supporters: it supports the belt.

4.8 Mechanical workshop
In mechanical shop we have been working in different operations by using different machines in
different purpose and also that working maintenance for machine parts. Different section found
in mechanical shop some of are:
 Production section and
 Welding Section
4.8.1 Production section
A. Lathe machine
Lath machine is the machine used for operations of circular (for circular cuttings) such as
turning, drilling, boring, facing, chamfering, threading, key way shaping, and tapper turning.
The capacity of lath machine in diameter is up to 2000mm. The maximum length of shaft is up to
4000mm.
Observation: -types of materials machined in lathe machine in my observation are: -
 Chamfering of stain less steel at 300 for weld training
 Grooving (tapper turning) of shafts for pulleys
 Threading
 Facing of the flange for the fuel tanker exhaust
 Boring
 Centering and circular tracing for the bolts of the flange for the fuel tanker exhaust

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Figure 4. 6 lathe machine

B. Drilling machine
Drilling machine is the machine used to materials by applying rotating drilling tool on fixed
material (work piece). It may drill radially or axially.
The capacity of drilling machine is measured due to the diameter of drill and the length of drill
(length of hole). It is possible to drill minimum diameter of 6mm and maximum diameter of
24mm by upgrading from 6mm.

Figure 4. 7 drilling machine

C. Hydraulic Press Machine

Hydraulic press is a type of force multiplying machine used for hard duties; which needs large
force. Using that large force, it can be used for different operations such as pipe bender. By
preparing different shapes (dies) it is applied for different shapes. In that machine it is possible to
assemble and disassemble force fit materials such as pressed shafts, axles, bearing and housing
etc.

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Figure 4. 8 Hydraulic Press Machine

4.8.1.4 Milling machine
In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges.
For cutting operation, the work piece is fed against the rotary cutter. As the work piece moves
against the cutting edges of milling cutter, metal is removed in form chips. Machined surface is
formed in one or more passes of the work. The work to be machined is held in a vice, a rotary
table, a three jaw chuck, an index head, between centers, in a special fixture or bolted to machine
table. The rotatory speed of the cutting tool and the feed rate of the work piece depend upon the
type of material being machined.

Figure 4. 9 milling machine

4.8.2 Welding Section
Welding is the process of joining metal parts uses electrode metal by melting and then
solidifying.

4.8.2.1 Arc welding

 Group of welding operations in which heating of the metals is accomplished by an
electric arc. Some operations also apply pressure & use a filler metal.

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 It is also called Shielded Metal Arc Welding (SMAW)

 Welding heat is generated by electric arc established between the electrode and work.
 Combustion of electrode gives off a gaseous shield to protect the weld puddle, arc, and
heated work from atmospheric contamination.
 Additional shielding provided by covering of molten slag (flux)

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CHAPTER 5

OVERALL INTERNSHIP BENEFITS

1. Improving practical knowledge

Internship program is very essential in terms of improving many practical skill, interpret the
theoretical knowledge into real. However, the skills and sound grasp knowledge’s nurtured by
studying engineering practically enables students to analyze and interpret diverse complex data.
Critical thinking and the ability to understand maintenance, repair, Controller and different work
activities. Inter personal communication, persuasiveness and the ability to work as a team and
individual confidence.

2. Upgrade theoretical knowledge

Even though, we have learnt a lot of things in the class theoretically, we got many knowledge
full activities while we saw things practically. Therefore, internship program was not only used
to improve our practical skill, but also used to impose my theoretical knowledge by correlating
the practical skill with theoretical knowledge. The main points that we have got theoretically:

1. About chain and elevator systems in detail

2. We knew the details of mechanical machine parts one by one; machine tower, standby
generator, boiler, compressor, generator, condenser, grain cooler, fans, pump and etc.
3. To correlate the theoretical knowledge with the real work.
4. We gain the knowledge of method of machine maintenance.
5. We knew the process of plant one by one.
6. We gain the knowledge of automatic stand by generator for emergency purpose.

Improving team playing skill

The most important point in team playing skill is just reach an agreement from different points
on the work to be done. For instance, in the case of applying kaizen working principle all the
factories worker was participating to insure the targeted goal in addition, the technique division
head, senior planners, Forman’s and mechanics discusses on issues that led them to the team
working.
1. Thus achieving good team playing skill is essential for:

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2. Grasping a good knowledge.

3. Communication skill is developing.
4. Increasing understanding of the task
5. Effective completion of tasks.
6. Saving times and increasing productivity

Improving Leadership skill

Leadership was one of the functions of management which including Planning, organizing,
stetting, leading and controlling. This internship program guides me to be an ethical leader that
means ethical leadership provides the momentum, guidance and motivation among members,
significant traits for effective leadership in my working area. In addition to this the internship
program allow me what a good leader satisfied or fulfill like a change agent innovative skill and
entrepreneur for himself. Therefore, this is a good collaboration between the leader and his staffs
the company or the agency also successful or fruit full. Generally, what we understood for the
past four months Internship program is that anyone who is willing to make the effort can become
a good leader.
Understanding about work ethics and related issues
Work ethics are generally accepted guidelines for right and wrong behaviors in work place. As
workers made to specialize in different fields specific codes of conduct were expected from each
worker. In today’s complex world, ethical conduct of workers is very important for developing
healthy working environment and increasing productivity. While we were in the factory most
workers told me what misbehavior cause workers to disappear from their working area. The
following principles allow good work ethics in working area. Punctuality, Honesty, Willingness
to learn, Initiative, Loyalty, Maximizing productivity.
 The following are the ethics that we get;
 We observe group work was better than individual work.
 We learn that no need of playing during work.
 Saving money and time was must within the work ethics.
 We observe that safety was first for work.
 How we were being punctual.

Entrepreneurship skill

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Entrepreneur is a person who sees a good opportunity for a new business and works hard to
make it grow. Entrepreneurs are very important for the growth of economy. While we was in the
factories, we have got wide knowledge in the entrepreneurship skill that we should have to find
ourselves as an engineer and creative person by analyzing work opportunities and employee. The
major characteristics of entrepreneurship that we have seen in the factory include the following;

Self-confident and multi- skilled: to be an entrepreneur engineer for the future we should have
to be confident to take positive or negative consequence. Therefore, the past four moth internship
programs lead me to a multi skilled engineer this skill creates confident in face of difficulties and
discouraging circumstances.

Innovative skills: a good skilled engineer can create a new mechanism in case of a difficult
challenge is occurring in the factory. Therefore, the past four moth internship program gave me
wide hint how we innovate if we were subjected to a difficult challenge.

Results oriented: to be successful it requires the drive that only comes from setting goals and
targets and getting pleasure from achieving them.

A risk taker: the successful entrepreneur exhibits as incremental approach to risk talking at each
stage exposing myself to only a limited measured amount of personal risk and moving from one
stage to another as each decision is proved.

Total commitment: hard work and energy are essential elements in the entrepreneur profile.
Finally, with this changing nature of work students must be enterprising and flexible and may
need to become entrepreneurial.

Improving interpersonal communication skill

Team working was priceless while performing tasks that make the factory profitable. To do
activities and works alone in the factory is a difficult task. Therefore, by good communication
among the different sections in the factory we grasped wide knowledge. Good communication
has the following advantage;

 Analyze and perfect performance of targeted maintenance and inspection.

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 Improving efficiency of the factory from some defect due to inter personal
communication.
 To handle information, the more we communicate with the different section in the
factory, the better we handle the information.
 To improve relationship with others if our day to day communication increases
my relationship among the different sections also improved.

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PART II

CHAPTER 1

1.1 INTRODUCTION

The portable crane is a product selected into the application of design axiom for this project.
Portable crane is a small crane that can be broken down into several parts for ease of
transportation. It must be assembled and bolted into a place where to be used effectively.
Portable crane designed for a whole range of floor lifting job. They are transportable and require
no external power. They can be used where no overhead lift is available and relatively short lift
required. It also increase efficiency and productivity while decreasing operator bending and risk
of back injury. The portable crane is widely used in mechanical engineering filed for assist any
heavy duty job. There are various types portable crane that are available in the market with a
various function and features.

Types of Portable Crane

Thus cranes are broadly categorized into three.

1. Overhead crane: - it is being used in a typical industrial shop. The hoist is being
operated via a wired push button station to move system and load along any
direction .un overhead mechanism crane is also known as a bridge crane where in
the hook and by line mechanisms runs along two widely separated rails. Overhead
crane is typically consists of lifter single beam or double beam construction. It can
be built by using typical steel beam or more complex box grinder type. Double
Grinder Bridge is more typical when there is a need for heavy capacity system of
10tons and above. The basic components of overhead cranes are the hoist to lift
the item, the bridge, a trolley to move along the bridge. Most of the time over
head cranes are applicable in steel manufacturing industry and vehicle/truck
production industry
2. Fixed cranes: - Fixed cranes are preferable in order to insure the ability to carry
heavy reaches greater heights due to increased stability.

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These types of cranes are characterized by the fact that their main structures does
not move during the period of use. However many can still be assembled and
disassembled. The structure basically is fixed in one place. There are many
different types of fixed cranes such as Tower cranes, self-erecting, telescoping,
Hammerhead, Gantry and Deck cranes, jib cranes, and bulk handling cranes.
However most of them are used under construction sites. Only few of them like
jib cranes Gantry and deck cranes are used in mechanical engineering operations.
3. Mobile cranes: - for effective and versatile operation cranes can also made to be
mobile. Mobile cranes are designed in different manner in order to be used on the
road, rail, water and air. There are many different kinds of mobile cranes. That are
truck mounted, side lifter, rough terrain, all terrain cranes, pick, and carry cranes,
telescopic handler crane crawl crane, pail road cranes, floating Aerial crane and
also portable crane.

1.2 Problem of Statements

In Asella malt factory there are four working section place. From those we have visited most of
them and there we have observed many drawbacks. All of the components are transported from
store to the factories by using man power, small crane and to lift material by using fork lift which
needs cost for fuel consumption and harmful on the workers. Also during the chemical spray in
the germination room to avoid algae due to moisture of the green malt in the roof and floor; the
workers use their hands to spray it. Similarly, after the product is packed to sell, the workers pull
the sacks on the floor.

1.3 Proposed solution

We proposed different solutions to save the downtime occurred, man power, fuel consumption
and any other related problems. Such as lifting crane,

1.4 Objectives

1.4.1 General Objectives

The general objective of the project is to design moveable lifting crane.

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1.4.2 Specific Objectives

 To design vertical column, boom, cylinder, base plate, hand bar, wheel, hook, chain, and pins.
 To determine the overall cost of the portable crane.
 To design the 3D model of all component of machine and assembly of the completed
machine.
 Animation of the machine to show working principles of the machine.
1.5 Methodology
The methodology incorporated in design and development of portable crane in Assela malt
factory is indicated as follows;
1. Primary source
 Direct observation
 Interviewing employees of different expert
2. Secondary source
 Reference
 Different websites
3. Data analysis tool
 Catia software
 SOLID EDGE software
Mostly we concentrate on the primary source of data to achieve our design appropriately by;
 Asking technicians about problems of the company
 Identifying the problems in the company
 Understanding operation principles of the machine
 Identifying part components which are needed for the machine
 Checking availability and manufacturability of those components
 Selecting materials for each component
 Analyzing each component strength wise
 Choosing method of joining for components
 Assembling orderly
1.6 Significance
 Our project can lift heavy loads about 3 ton that is beyond the capacity of human being
applying only small force in the factory.

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 The costs of the materials are relatively cheap hence it can be used widely and can be made
by local materials.
 Flexibility and movability
 Capable of reaching everywhere and anywhere.
1.7 Limitation
The limitations of our project are;
 Our project can’t lift loads beyond 3 tons.
 Can’t lift the loads beyond 3 meters.
 Since it moves manually it requires time.
 Lack of part manufacturing

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CHAPTER 2

2.1 LITERATURE REVIEW

The development of lift machine or crane has reached through different time starting the first
crane for lifting heavy load was invented by ancient Greeks in the late 6th century BC. The
heydays of crane in ancient times come during Roman Empire when construction activity soared
and buildings reached enormous dimensions. The Romans adapted the Greeks cranes and
developed it further. The simplest Romans crane is the trespasses, which consists of a single
beam jib, a winch, a rope, and a block containing three pulleys. Having this mechanical
advantage of 3:1, it has been calculated that a single man working the winch could raise 150kg
[3pulles*50kg=150kg], assuming that 50kg represent the maximum effort of a man can exert.[6]

Over a long time period heavier crane type featured five pulleys (pentaspastos) or in case of the
largest one a set of three by five pulleys (polyspestos) and came with two, three, or four masts
depending on the maximum loads. The polyspastos when operated by four men at both side of
the winch could readily lifts 3000kg[3 ropes*5 pulleys*4 men*50kg=3000kg] If the winch was
replaced by a trade wheel, the maximum load could be doubled to 6000kgs, because the trade
wheel have much bigger mechanical advantages due to its higher diameters. This means
comparing with the construction of Egyptian pyramid where in 50 men are needed to move 2.5
tons of stone up the ramp (50kg per persons).

The lifting capability of the Roman polyspastos is proved to be 60 times higher than the Egyptian
system of lifting stones. During the high middle age the trade wheel was introduced on large
scale after the technology had fallen in the Western Europe with dismiss of Western Roman
Empire. The earliest reference to the trade wheel reappears in the archival literature in France
about 1225. Generally vertical transport could be done more safely and inexpensively by crane
than customary method. Typical areas of application were harbors, mines, and in particular
building sites where the trade wheel crane played a pivoted role in the construction of lofty
Gothic cathedrals.

In contrast to the modern cranes, middle age cranes and hoists –much like to their counter parts
in Greece and Rome were primarily capable of a vertical lift, not used to move loads for

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considerable distance horizontally as well. It is not worthy that middle age cranes rarely featured
ratchets or brakes to forestall the loads from running backwards.

This curious absence is explained by a high friction force exercised by middle age trade wheels,
which normally prevented the wheel from accelerating beyond control. With the onset of the
industrial revolution, the first modern cranes were installed at harbors for loading cargo.

In 1838, the industrialist and business man sir William Armstrong designed a hydraulic water
powered crane .His design used a ram in a closed cylinder that was forced down by a pressurized
fluid entering the cylinder. Thus the valve on the cylinder regulates the amount of fluid intake
relative to the load on the crane. [6]

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CHAPTER 3

WORKING PRINCIPLE AND 3D

Working Principle
Its working principle is that the part to be lifted (the motor, machine components, heavy metal
etc.) is suspended on the hook by adjusting the boom by the actuator using the fluid and applying
the hand pump by holding down and up so that the piston extends against the load, in turn the
load is lifted. The height and the amount of weight to be lifted are adjusted by extending or
retracting the boom out of or into upper frame. The loaded lifting machine is moved to the
desired place by the simple push of handle. The machine also has a feature of becoming compact
for the purpose of using available space, storing and transportation.

Figure 3. 3 Portable crane

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Parts of portable crane

a. Vertical column

Vertical column is supporting components. It holds the boom, cylinder, hand bar and attached to
the base plate. It maintains the rigidity of the crane. The maximum lifting distance of the crane is
depend on the length of this component. It is made of high strength metal.

Figure 3. 4 Vertical column

b. Boom
The boom is modeled as simply supported beam, and it is subjected to a bending stress due to
bending moment developed at the fixed end where it is pinned with the vertical column. Boom is
the component on which the hook with chain is attached. Also it is connected to the vertical
column with actuator to lift up and down the load.
c. Cylinder
The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic
cylinder usually made of cast steel or cast iron, But for our design purpose we select cast steel
because of high heat resistance, easily machine able and low cost.

Figure 3. 5 cylinder

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d. Base plate

Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In
addition it carries the load by all the components of the crane .It is composed of four bars and
each of them is modeled as a beam. Bar 1 and Bar 2 are side bars on which the center connecting
bar is supported over. And the other is end bar which is provided at the back end of the two side
bars to give extra strength. To know the stress developed in these components first we should
know the all loads applied and let’s first calculate all the masses of all the other components.

Figure 3. 6 Base plate

e. Hook

Hook is the component which is fixed with the boom and it is used for hanging the load on the
boom which moves up and down in lifting the load.

Figure 3. 7 hook

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CHAPTER 4

DESIGN ANALYSIS OF COMPONENTS

4.1 Design of Vertical Column

Figure 4. 10 Vertical column

Where:-

 k= is radius of gyration
 c= is distance between column
 e= is eccentricity of load

Therefore: c=0.15m/2, e=1.6m

The column cross section subjected to compression stress is

Figure 4. 11 Cross-section of vertical column

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The area of column cross section is

A= [(0.15*0.13)-(0.116*0.136)] m2= 3.724*10-3m2
Moment of inertia
Ixx=[(0.15*0.13)3-(0.116*0.136)3]/12
Ixx=0.97725*10-5m4
Iyy=[(0.13*0.15)3-(0.136*0.116)3]/12
Iyy=1.2209*10-5m4
NOTE: Buckling always occurs about the axis having minimum radius of gyration or least
moment of inertia, therefore in our case buckling occur along horizontal direction (Ixx).

√
K=√ I XX / A =
0.97725∗10−5
3.725∗10
−3

=0.051226891m
σ C =¿Pvc/A (1+ec/k2)

P= 3000*9.81 m/s2
=29.43KN

PVC=P/ (COS12)0

PVC=30.1KN

σ C =30.1KN/1.911*10-3m2 [1+(1.6)(0.075)]/(0.051226891)m2

=15.751*10-6N/m2[1+45.72832]

=794.024*106N/m2

σ C =736.0.13MPa

Note:-Load that the vertical column subjected to is compressive, and material for the column is
selected to be cast iron, because it has low cost, good casting, and high compressive stress. It is
primarily made of carbon and iron with carbon content of 1.7% to 4.5%. The maximum value of
crushing stress (σc) that will develop in cast iron is given to be 400MPa to 1000Mpa. Since the

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induced compressive stress due to the applied load is not greater than the maximum crushing
stress developed in the cast iron. Therefore the vertical column is designed safe. [2]

4.2 Design of Boom

Figure 4. 12 Boom connected with column

σ b = M/Z

Where

 Z= Section modulus
 M= bending moment at point A
 bending stress

Since the boom is hollow rectangular cross section, the area of boom to which the effect of load
P induces the stress is: A=16(0.12-0.108)

A=0.0192m2

Figure 4. 13 Boom section view

 Moment of inertia

IXX=1.6(0.12*-0.108)/12

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IXX=6.24384*10-5m4

Distance from neutral axis extreme fiber (c) is;

C=0.12/2=0.06m

 Section modulus

Z=I/C = [6.24384*10-5/0.06]

Z=1.04064*10-3m3

 Bending moment, M is

M=P*L, L is length of boom

=29.43KN*1.6=47.088*103Nm

σ C =¿M/Z

=47.088*103/1.04064*10-3

σ C =45.25MPa

NOTE:- material selection of boom Since the load applied on these components is high the
material used to make these components should be strong and hard, thus the best material suited
for is steel which has carbon content of up to 1.5% which results in an increased strength and
hardness. The material selected for the boom is standard Steel Fe E-520-Indian standard
designation, and it has a minimum yield stress of 520Mpa and the allowable bending stress is;

σ b=¿Sy/n

n=factor of safety which be assumed n=4

=520MPa/4

σ b=130MPa, Allowable bending stress.

Since the allowable bending stress developed is greater than the induced bending stress due to
the load applied, then the boom is designed safe.

4.3 Design of Crane Hook

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Figure 4. 14 Plane view of crane hook

Figure 4. 15 Cross section of crane hook

rc = r1+h/2 and

rn = h/Ln

Due to the applied load the hook is subjected to tensile and compression stress with moment;

M=P*rc

Normal stress

, rn-y=r

But rc=3cm+4cm/2=5cm

rn=4/Ln(7/2)=4.72cm

e=rc-rn=5-4.72=0.0028m

Cross sectional area at which the load act is

A=2cm*4cm=8*10-4m2

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Moment due to the load applied is, M=p*rc

M=29430N*0.05m

M=1471.5Nm

Substituting r from 3 to 7 we can determine the stress developed in compression and tensile side.

For r=3cm

σ =29.43KN/8*10-4+1471.5 (0.0472-0.03)/(8*10-4(0.0028)(0.03))

σ =413.421MPa

For r=4cm

σ =29.43KN/8*10-4+1471.5 (0.0472-0.04)/(8*10-4(0.0028)(0.04))

σ =155.0.255MPa

For r=5cm

σ =29.43KN/8*10-4+1471.5 (0.0472-0.05)/ (8*10-4(0.0028)(0.05))

σ =0MPa

For r=6cm

σ =29.43KN/8*10-4+1471.5 (0.0472-0.06)/(8*10-4(0.0028)(0.06))

σ =-103.355MPa

For r=7cm

σ =29.43KN/8*10-4+1471.5 (0.0472-0.07)/(8*10-4(0.0028)(0.07))

σ =-177.1806Mpa [2]

NOTE: - material selection for the crane hook crane hook is subjected to both tensile and
compressive stress, and wrought iron is selected for it, because it is malleable tough and ductile
material. It has carbon content of 0.02%, 0.12% silicon, 0.018% of phosphorus, 0.07%of slag,
and the remaining is iron.

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since the induced tensile and compressive Stress are less than for the crane hook, i.e. wrought
iron which have a stress of 250MPa to500MPa and 300MPa under tensile and compressive
respectively, then hook is designed safe. The ultimate tensile and compressive stress of the
material that is selected

4.4 Design of Base Plate

Figure 4. 16 Base plate

Masses of vertical column:

Figure 4. 17 Vertical column

Volume vertical column

V=A*L

= [(150*130)-(136*116)]*1800

V=0.0067032m3

Since the material for the vertical column is made from cast iron, the mass density of cast iron is
7250kg/m3.

ρ =m/V, m= ρ V

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m=7250Kg/m3*0.0067032m3

mV =48.6Kg mass of vertical column

Mass of Boom:

Figure 4. 18 Boom cross section

The volume of the boom is

V=A*L

V= [(1200*1200)-(1060*1060)]*1600

V=0.00506062m3

The boom is made of standard steel, and the mass density of steel is 7850kg/m3

ρ =m/V, m= ρ V

m=7850Kg/m3*0.00506062m3

m=39.7Kg mass of boom

Mass of vertical column support:

Figure 4. 19 Vertical column support

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V=A*h

= [(60*70)-(52*62)]*1200

V= 0.0006048m3

The material for the support is selected to be cast iron, which have mass density of 7250kg/m3.

ρ =m/V, m= ρ V

m=7250Kg/m3*0.0006048m3

m=4.4Kg mass of vertical column support

Mass of crane hook:

The cross sectional area of crane hook is assumed to be equal to thin circular plate of 6cm inner
diameter and 14 cm outer diameter having a thickness of 2cm.

V=A*t

= [(do2-d12)/4]*t

= (72-32)*2

V=62.832*10-6m3

Since the material for crane hook is wrought iron, which have mass density of 7780kg/m3,

ρ =m/V, m= ρ V

m=7780Kg/m3*62.832*10-6 m3

m=0.5Kg

The mass of other components like hydraulic tank with the fluid, hydraulic cylinder , pin , bolts
with nut, all in one are estimated to be 25kg.Additionally the design is proposed to lift a load of
3000kg ,and the total mass applied on the base plate is,

MT= [48.6+39.7+4.4+0.5+25+300] Kg

=3118.2Kg

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PT=mT*g

=3118.2Kg*9.81m/s2

PT=38.5895KN

4.5 Design of Center Connecting Bar

Figure 4. 20 Center connecting bar

Due to the load P, the bar is subjected to equal bending moment at both end of the plate. At both
end there are two reaction forces to encounter the bending of beam due to the load applied. And
these are equals to half the load applied.

R=15.294771KN

A= (200*80)-(193*73) mm2

A=1900mm2=0.0019m2

Section Modules

Z= (200*803-186*663)

Z=5.69*10-5m3

Moment at the two end of bar

MA,B =(PT*L)/4

=30.5895KN*0.516)/4

M=3.94605KNm

σ b=¿M/Z

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=3.94605KNm*5.69*10-5m3

=661.159*105N/m2

σ b =66.1159MPa, Induced stress

The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals 4

σ =¿Sy/n

=520/4=130MPa

Since the induced stress is less than the ultimate bending stress, then the bar is designed safely.

4.6 Design of Pins

Pin 1 Due to the load applied at the end of the boom and the load by the boom itself, the pin that
connect the vertical column and the boom is subjected to shearing stress. The shearing force
applied on the pin that connects the vertical column with the boom can be obtained using the
principle that summation of moment on the pin that connects the actuator and boom is zero.

∑ M B=0

Figure 4. 21 Pins of portable crane

0.7(RC) =0.1(W) + 0.9(P)

W=39.7Kg*9.81m/s2

W=389.457N

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P=29.43KN

RC= (38.9457+26487)/0.7

RC=37.894208KN shear force on pin 1

Since the pin is subjected to high tensile and shearing stress, the material for the pin should be
ductile. And the material selected is mild steel. We have selected Fe 690 which has minimum
tensile strength of 690N/mm2 and minimum yield strength of 410N/mm2. [2]

τ Max =Sy/2n

τ Max =25.625MPa

Figure 4. 22 Pin supporting vertical column and boom

Thus the pin will be subjected to double shear and then the pin is designed as follow.

τ =P/2A, P is shear force

A =Area subjected to shear stress

A=RC/2τ ,

π *d2/4 = RC/2τ ,

d=√ 4 R C /π 2 τ

= (2*37.894208*1000N)0.5/ ( π *25.625N/mm2)

=30.6827mm

Say d=32mm, diameter of pin at lower extreme

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When the actuator is at its upper extreme, the pin that is used to connect the vertical column with
the boom is designed as follow. Reaction at point C is obtained by applying the principle that
summation of moment about point B is zero.

RC (0.7) cos71.45o=W (0.1) cos(71.45o) * P(0.8)cos71.45o

RC=33689.92N

d=√ 4 R C /π 2 τ

=
√ 2∗33689.92
π∗25.625

d=28.93mm, diameter of the pin when the actuator is at its upper extreme

Taking the larger of the two is safe, and the pin that connects the vertical column and the boom
should be 32mm of diameter. The length of pin is slightly made to exceed the width of vertical
column, that is

L=150+15

L=165mm

Similar way; for pin 2, d = 28mm. Pins for the Actuator, d = 74mm

Note:-In our project pins are subjected to tensile and shearing. The material selected for the pin
should be ductile and we have selected mild steel.

4.7 Design of Hydraulic System

Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator that is used
to give a unidirectional force through a unidirectional stroke. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically hydraulic oil. Design of hydraulic cylinder
consists of design of cylinder, design of piston rod, hinged pin, design of flat end cover design
of piston,

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a. Design of Cylinder
The values taken for our design are;

σ t= permissible tensile stress

=80N/mm2

P=Maximum pressure inside the Cylinder

=3.5N/mm2

F=load that is applied on the actuator

=212615.4189N

Then, inner diameter of the cylinder is (di):-

F=p* π di2/4

di=√ 4 F / πp

di =
√ 4∗212615.4189
3.5∗3.14

di =280mm, Say Thickness of the cylinder;

Let, t= thickness of the cylinder

t=ri[(√ σ t + p )/(σ t− p )-1]

Where, ri = di/2= 280mm/2=140mm

t=140[(80+3.5)0.5/ (80-3.5)-1]

t=9.22mm

Outer diameter of the cylinder

Let, dO = Outer diameter of the cylinder

dO =di+ 2t =280mm+ 2* 9.22mm= 298.44mm

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The cylinder head may be taken as flat circular plate whose thickness may be determined from
the following relation.

Let, th = is the thickness of the head

σ C = allowable circumferential stress in N/mm2

=30 to 50Mpa.

Take, σC = 40Mpa (for our design purpose)

th=di(c* p/ σC)

Where = is constant=0.1.

th=280mm(0.1*3.5N/mm2/40N/mm2)

=26.2mm

And the length of cylinder is:-

L=2*dO

=298.44*2=596.88mm

b. Design of Piston
Piston is moved by a fluid, or it moves the fluid which enters the cylinder. The most commonly
material used for piston is cast iron, cast aluminum, forged aluminum, cast steel, and forged
steel. But the material we selected for our design purpose is cast iron.

Piston is consists of the following parts, Head or crown, Piston ring, Skirt, Piston pin, Piston
head:-

The thickness of piston head (tH), according to Grashoff’s formula is given by:-

tH=√ ( 3 p ) (D0)/16 σ t ,where

p= maximum pressure
D0 =outer diameter of piston
σ t =tensile stress=38N/mm2

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Note: The outer diameter of the piston is assumed to be equal to the inner diameter of the
cylinder. Therefore the outer diameter of the piston is 280mm.

tH=
√ 3∗3.5∗280
16∗38

=4.8mm, say tH= 5mm

c. Design of Piston Rings

The piston rings are used to impart the necessary radial pressure to maintain the seal between the
piston and cylinder bore. The radial thickness (tr) of the ring may be obtained by considering the
radial pressure between the cylinder wall and the ring.

tr=DO√[(3∗Pw )/ σ t ¿ ]¿

Where

 DO=outer diameter of piston

 Pw= pressure on the wall of cylinder, limited to 0.025 to 0.042N/mm2
 σ t=Allowable tensile stress in Mpa, it may be taken 85MPa to 110MPa for cast iron rings.

tr=280mm√[(3∗0.035)/90 ¿ ]¿

tr =9.56mm
And also the axial thickness of the piston ring (ta) is:-
ta=0.7tT to tT
ta=7mm to 9.56mm, selecting
ta=8.5mm
We also know that the minimum axial thickness of the piston ring is:
t=Do/10nr
Where, nr=No of rings=4
ta=280mm/10*4
ta=7mm
Thus the axial thickness of the piston ring as calculated (i.e. ta = 7mm) is satisfactory. The
distance from the top of the piston to the first ring groove, i.e. the width of the top hand:-

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b1= tH to1.2 tH
= 5mm to6mm, taking, b1= 5.5mm
And the width of the other hand of the ring
b2= 0.75ta to ta
= 6.63mm to8.5mm, taking, b2= 7.5mm.
We know the gap between the free ends of the rings:
G1= 3.5tT to4tT
= 33.46mm to38.24mm
And the gap when the ring is in the cylinder,
G2=0.002D0 to 0.004D0
=0.56mm to 1.12mm, lets select
G1=36mm, and G2=1mm

d. Design of Piston Barrel

It is a cylindrical portion of the piston. The maximum thickness (t 3) of the piston barrel may be
obtained from empirical relation:

t3= 0.03Do+ b+ 4.5,

Where b = radial depth of piston, and it is taken to be 0.4mm greater than the radial thickness of
piston ring

I.e. b = tr + 0.4mm
Therefore, t3 = 0.03DO + tr +4.9
t3= 0.03(280) + 9.56 +4.9
=22.86mm, say
t3 =23mm
And the piston wall thickness (t4) towards the open end is decreased and should be taken as:-
t4= 0.25t3 to0.35t3
= 0.25 (23) to0.35 (23 mm)
= 5.75to8.05mm, Adopting

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t4= 8mm

4.8 Lifting Height

• The maximum height that the crane can lift is obtained as follows.

Figure 4. 23 height of the crane at maximum height

From cosine low:
(1 107.6)2= (172)2+ (70)2- 2(172) (70) cos(a)
α= cos-1 [0.9512]
α = 17.96°
From sin low:
Sin17.960 /107.6 Sin β /70
β =Sin-1[0.20056]

β =11.570
θ=¿1800-[17.96+11.57]0

θ =150.460

M=160Sin (60.46)0=139.2cm
N=107.6cos (12)0=105.24cm
K=53cos (12)0=51.84cm
H=M+N+K=314cm
H=3.14m

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• Minimum height that the crane can pick up objects from is obtained as:

Figure 4. 24 Height of the crane at minimum height

From Cosine law:

θ =Cos-1[(107.6)2+(70)2-(107)2]/2(107.6)(107.6)

θ =70.490 M=160cos (82.49)0=20.99cm h=160cos (12)0-M h=135.5cm

CHAPTER 4

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COST ANALYSIS, MANUFACTURING AND MATERIAL

SELECTION
A. COST ANALYSIS

For any application there is a limiting cost beyond which the design cannot go. When this
ultimate exceed we have to be consider another alternative solution or materials.
In cost analysis there are two factors namely; cost of processing the material into finished goods
and materials cost. It is likely that the cost of the materials must be low but, the processing may
involve costly manufacturing process. Cost analysis means the cost that the project takes or costs
to buying the material we use do this project.

NO Material Cost(birr) Quantity Total price

1 Boom 2000 1 2000

2 Vertical column 2500 1 2500

3 Base plate 2400 1 2400

4 Hook 1800 1 1800

5 Pin 300 8 2400

6 Cylinder 2500 1 2500

7 Piston 1000 1 1000

8 Piston rings 280 1 230

9 Piston barrel 250 1 250

10 Wheel 200 4 800

Total 18 11930

Table 1 Table of cost of material

B. MANUFACTURING PROCESS

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components Manufacturing processes

Vertical column, boom and hook Milling, hardening, tempering, surface

grinding

Actuator, Drilling, milling

Base plates Milling ,drilling, welding

Pins, bolts and nuts Turning, threading

Cylinder, piston and piston rings Drilling and different machining

operations

C. MATERIAL SELECTION

The selection of a material for a machine part or structural member is one of the most important
decisions that the designer is called on to make. To prepare any machine part, the type of
material should be properly selected, considering design and safety. Selection of material for
engineering application is given by following factors. Availability of material, suitability of the
material for the required component, cost of the material, strength of the material We have used
different types of steels for this design, but most of the materials for this machine use mild steel.

CHAPTER 5

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5.1 RESULT AND DISCUSSION

Component Result Material used

Hydraulic inner cylinder diameter 576mm AISI 1045 steel

Thickness of cylinder 10 mm

Outer diameter of cylinder 596 mm

Diameter of piston head 15 mm Cast iron

Diameter of piston rod 7 mm

Piston length 600 mm

Vertical column 1136.7 mm Cast steel

Boom, hook 0.036 mm

Table 5. 1 material analysis

5.2 CONCLUSION

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For many years cranes have been designed for lifting heavy objects with different capacity in
different work sites. Portable cranes are of one type of cranes designed for lifting objects which
are beyond the capacity of human being. As Assela malt factory is one of the companies where in
many different lifting operation is practicable. Lifting of different material by using portable
crane which is not being use before, we have identified that there is the need for using portable
crane to lift up objects these are beyond the capacity and difficult of human power. Thus this
paper provides the design of each part of portable crane. And the design analysis for each part is
checked that it is safe accordingly the size of each parts of the crane. Similarly, it decreases loss
of time and increases production rate. It also increases the income of the company by decreasing
unnecessary expenditure. We can also use this machine for maintenance service not only in this
company also all other Garages. This machine is manufacture by easily available materials. The
maximum carrying capacity 3 ton, and maximum lifting height is estimated as greater than
3.14m from the ground run by using hand pump of hydraulic system.

In general, the four-month industrial internship program gives me a great knowledge about our
working area very well. In addition, the practical activities that a mechanical engineering should
have to do when the student are participating in the external world. After our four-month
industrial internship that we spent on Assela Malt Factory we have understood many issues. This
program allows upgrading student’s practical and theoretical knowledge; in addition it improves
the inter-personal communication skill among other individual workers and employees on the
hosting company. Under some circumstances newly graduated engineering students to the actual
existing outside world. Students have go challenge when they employed on the companies due to
lack of practical knowledge. But this industrial internship can resolve such kinds of thing by
preparing. This internship program also increases student’s self-confidence to take an action and
taking responsibility on the task given to them. In my case we have been taking such disciplinary
actions while we were performing planning activities. This program enables me to be hard
worker and a successful engineer for the future, because mechanical engineering is not only
theoretically but also practically a tiresome job activity.

5.3 RECOMMENDATION

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As internship program gave an opportunity to change the student to change theoretical

knowledge into practical or real world and exposes the student to exercise the real world life, we
strongly recommended to be continue in a manner that it achieves its goal.
Furthermore we recommended Asella malt factory the following points.
Asella malt factory should;
 Depend on what we have designed the next internship comer may get a hint to modify
or redesign this project.

 We suggest that the company to can manufacture and use this portable crane for its
production increments
Jimma University should;
 Follow our internship projects whether they are manufactured or not if they are
mandatory to manufacture.
 Communicate with workshop and maintenance office of company to help the students
to expand their capacity by designing new machine, modifying the existing machine
and also implementing designed machine for the company to reduce the extravagance
of costs on maintenance to overcome related problem identified in company.
 Give workshop course for students to increase effectiveness and advise them during
construction.
 Fulfils the materials required for the construction of machine

5.4 REFERENCE

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[1] Asella malt Factory source document.

[2] R.S. Khurmi and J.K. Gupta. “Text book of Machine design” 8th edition, EUROASIA
PUBLISHING HOUSE (PVT.) LTD .2005.

[3] Budynas-Nesbett. “Shigley’s Mechanical Engineering Design”, 8th edition, McGraw Hill
companies, 2008.

[4] Machine design data book.

[5] https://www.hydraulics.com/hydraulic-portable crane/

[6] Fundamentals of modern manufacturing Materials, Processes, and Systems Fourth Edition.

5.5 APPENDIX

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i. Base plate

ii. Cylinder

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iii. Boom

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iv. Vertical column

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v. Tire

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vi. Hand bar

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vii. Hydraulic crane

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